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DMG
Aerospace Industry
www.gildemeister.com DMG – innovative technologies
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Complete machining of a
compressor housing with a
DMC 160 FD duoBLOCK® -m
and turning in a single setu
FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 7
Complete machining of a
compressor housing with a
DMC 160 FD duoBLOCK® -milling
and turning in a single setup.
FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 8
DMG – Your High-tech partner in theglobal aerospace process chain.
Unlike any other company, DMG has a complete range of machine tools for
the aerospace manufacturing sector. We offer complete Milling / Turning
machines and for new machining methods, we offer Ultrasonic and Laser
technology. To compliment our machines DMG Service Solutions provides
complete training, software and tool measurement products to enhance
your production performance.
Integrated milling and turning centers manufacture turbine components made
from high-strength materials, vertical lathes deliver maximum productivity
in the cylinder production of aircraft motors, LASERTEC 80 PowerDrill
machines have revolutionized the production of shaped holes in engine manu-
facturing, and the duoBLOCK© portal machines in the DMU / DMC Series
deliver maximum performance for sophisticated 5-axis / 5-sided machining
in the production of integral aluminum components.
All these are examples of DMG – the global partner for the international
aerospace industry.
321 The 3 main groups in the
DMG application spectrum:
|1| Structural components
|2| Engine components
|3| Landing gear com-
ponents
FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 5
DMU / DMC duoBLOCK® Series – The right solution for every 5-axis machining task.The duoBLOCK®-design from DECKEL MAHO has become the standard strategic platform for milling
applications up to 4,000 kg and has led to unprecedented flexibility in the manufacturing of parts such
as bladed disks (blisks), casings and housings.
duoBLOCK® Series Production Highlights
Standard version:
_ Production package: Coolant tank 600 / 980 l, coolant through the
spindle center (40 Bar), chip conveyor and Rotoclear
_ High precision package: TPC (Table Precision Control) for the
identification and correction of the pivot point of the NC-rotary table;
HPC (Head Precision Control) for the identification and correction of
the pivot point of the spindle head
_ Chain magazine with 40 pockets (DMU 80 / 100 / 125P) or 60 pockets
Turning-Milling:
_ 5-axis milling and turning in a single setup
_ Electronic balancing on the machine
_ Concentric trueing in the setup area
_ Setup area with a powered rotary pallet (DMC 200 / 340 FD)
_ New FD-drives with DirectDrive technology, rotational speeds
up to 800 rpm., more torque (up to 40 kW) and max. table
loads up to 7,000 kg
Technical Data DMU 80 P | DMC 80 U DMU 100 P | DMC 100 U DMU 125 P | DMC 125 U DMU 160 P | DMC 160 U
X- / Y- / Z-axis mm 800 / 800 / 800 1,000 / 1,000 / 1,000 1,250 / 1,000 / 1,000 1,600 / 1,250 / 1,000
Main drive (40 / 100% DC) kW 28 / 19 28 / 19 28 / 19 28 / 19
Torque (40 / 100% DC) Nm 121 / 82 121 / 82 121 / 82 121 / 82
Speed range rpm. 12,000 12,000 12,000 12,000
(8,000 / 10,000 / 18,000)* (8,000 / 10,000 / 18,000)* (8,000 / 10,000 / 18,000)* (6,300 / 10,000 / 18,000)*
Feed and rapid traverse X/Y/Z m/min 60 60 60 60
Tool holder SK40 (SK50)*** SK40 (SK50)*** SK40 (SK50)*** SK40 (SK50)***
Number of magazine pockets 40 | 60** 40 | 60** 40 | 60** 60****
Table size (NC-rotary table) mm 900 x 700 | 800 x 630 1,100 x 900 | 1,000 x 800 1.,250 x 1,100 | 1,000 x 800 1,500 x 1,250 | 1,250 x 1,000
DMG ControlPanel with 15" TFT-screen and 3D-software,
Controls: Siemens 840D powerline, Heidenhain iTNC 530, Heidenhain MillPlus iT, Siemens 840D powerline
* Optional, ** Optional: 60 / 120 / 180 / 240 / 300 / 354, *** Optional: HSK-A63 / HSK-A100, **** Optional: 120 / 180 / 240
a
b
c
Spindle options for more complex machining
_ Automatic swivel milling head H / V
_ NC-swivel milling head as an A-axis for negative angles up to 30°
_ NC-swivel milling head as a B-axis
(swivel range 0 – 210°) with maximum rigidity
Spindle options for maximum flexibility
_ Motor spindle for HSC-machining
(10,000 rpm. to 18,000 rpm., 121 to 288 Nm)
_ Gearbox spindle for machining of heavy workpieces
(6,300 rpm. to 8,000 rpm., 727 to 1,100 Nm)
_ Aerospace spindle for max. chipping rates up to 10,000 cm3/min
(15,000 rpm. up to 30,000 rpm., max. 100 kW)
Table options
_ NC-rotary table
_ NC-swivel rotary table
_ NC-milling / turning table (up to 800 rpm.)
Automated production: Flexible manufacturing system with five DMC 160 FD
Milling-Turning centers for the fully automatic machining of combustion chamber housings.
a
b
c
FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 1
5 6
31
4
8 9
7
2
Landing gear components machined on the
DMU / DMC duoBLOCK® Series:
|7| Actor |8–9| Connecting bracket
sk.Structural components
ng
tive angles up to 30°
ty
)
kpieces
p to 10,000 cm3/min
W)
Landing gear components
Structural components machined on the
DMU / DMC duoBLOCK®-Series:
|1| Structural wing component |2–3| Structural fuselage
components |4| Structural wing component
|5–6| Structural fuselage components
FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 2
9
6 7
8
3 4
2
5
1Engine components machined on the
DMU / DMC duoBLOCK® Series:
|1| Plenum chamber housing |2| Combustion chamber
housing |3| Impeller disk |4| HP compressor housing
|5| Turbine housing |6| Compressor annulus
|7| Compressor turbine vane
Engine components
Engine components – machined on
LASERTEC 80 PowerDrill:
|8| HP turbine rotor blade
|9| HP turbine rotor blade guide vane
FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 3
The GMX linear Series – milling-turning centers for the 6-sided complete machining of complex workpieces.
LASERTEC 80 PowerDrill – The technological leader for the precise laser boring of turbine components.
Technical Data GMX 200 S | 250 S linear GMX 200 linear GMX 250 linear GMX 300 linear GMX 400 linear GMX 500 linear
Work area
Max. machining diameter mm 640 560 640 640 640 610
Max. machining length (with tailstock) mm 1,185 (1,180) 1,070 (1,000) 1,185 (1,180) 1,585 (1,500) 1,585 (1,500) 1,870 (1,850)
Max. bar diameter mm 65 (90)* 65 (90, 102)* 65 (90, 102)* 65 90 (102)* 102
Main- and counter spindle*
Max. drive power (40% DC) kW 28 (47)* 37 (45, 45)* 28 (47, 45)* 37 45 (45)* 69
Max. torque (40% DC) Nm 320 (730)* 390 (750, 750)* 320 (730, 750)* 390 750 (750)* 1,000
Turning- / milling spindle
Max. spindle speed rpm. 12,000 (18,000)* 12,000 (18,000)* 12,000 (18,000)* 12,000 (18,000)* 12,000 (18,000)* 12,000
Max. drive power (40% DC) kW 22 22 22 22 22 15
Y-axis / B-axis mm / degrees ± 90 / ± 120 ± 80 / ± 120 ± 90 / ± 120 ± 110 / ± 120 ± 110 / ± 120 ± 105 / ± 120
Tool magazine Disk Shelf Shelf Shelf Shelf Chain
Number of tools 36 46 (80)* + 4 46 (80)* + 4 60 (120, 180)* + 4 60 (120, 180)* + 4 40 (80)*
12-x turret head with tool drive*
Drive power (40% DC) kW – | 11.7 – 11.7 11.7 11.7 10
Torque (40% DC) Nm – | 28 – 28 28 28 42
DMG ControlPanel with 15" TFT-screen and 3D-software, Controls: Siemens 840D solutionline**, Siemens 840D powerline, Heidenhain PlusIT***
* Optional, ** only for GMX 200 S linear, *** only for GMX 250 S linear
GMX l inear Series Highlights
_ Linear drive in the Z-axis ensures maximum precision and
dynamics, rapid traverses up to 70 m/min
_ High-performance milling spindle with 12,000 rpm. and up to
120 Nm, swivel range 240°
_ CAD-data import and multi-axis milling with DMG Programmer 3D
Turning (optional)
_ DMG ControlPanel with 15" TFT-screen and Siemens 840D
powerline, 3D-simulation and collision monitoring (optional)
_ 12x-turret with driven tools
_ Shelf magazine for 60, 120 or 180 tools
LASERTEC Series Highlights
_ 5-axis laser precision boring of cooling air vents and shaped
holes in turbine components
_ Highest dynamics due to linear drives in X, Y, and Z,
with 1.2-g acceleration
_ Rotary- and turning axes (B- and C-axis) with torque motor
_ Special Lasertec turbine software for simple programming
and operation
_ Highly precise Nd:YAG-laser for boring and welding
Technical Data LASERTEC 80 PowerDrill LASERTEC 80 PD SHAPE
Number of machine axes 5 5
Work area X / Y / Z mm 800 / 500 / 700 800 / 500 / 700
Rapid traverse speed linear X / Y m/min 120 120
Max. workpiece weight kg 50 50
Machine precision P max. μm 10 10
Laser sources Nd:YAG or CO2 Nd:YAG
DMG ControlPanel with 15" TFT-screen and 3D-software
Control: Siemens 840D powerline
FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 4
DMG Vertriebs und Service GmbH: Gildemeisterstraße 60, D-33689 Bielefeld, Tel.: +49 (0) 52 05 / 74 - 30 13, Fax: +49 (0) 52 05 / 74 - 30 77, info@gildemeister.com, www.gildemeister.com
Our top priority is to provide you with
the best possible training for the per-
sonnel responsible for the operation
and maintenance of your machine tools.
You achieve the highest productivity of
your manufacturing processes with the
help of our practice-oriented training
with a global perspective, on machines
equipped with the most advanced tech-
nology. DMG training puts you on the
course for success and secures your
competitive edge.
As the largest global producer of metal
cutting machine tools and the tech-
nology leader for 5-axis machining,
DMG presents itself as the optimal
partner for the aerospace industry and
its suppliers. DMG is a master of all
aspects in the aerospace process chain,
from highly precise complete machin-
ing and HSC-milling all the way to the
revolutionary use of future-oriented
laser technology.
Rotary and linear magazines
Take advantage of our customized
service products and service support
options for the entire life span of your
DMG machine tools and systems.
Our expert Service Hotline and DMG
Netservice ensures highest produc-
tivity and availability for your opera-
tions. DMG Spare-parts Service offers
the best availability worldwide and the
shortest delivery times.
DMG technology and key competency
DMG TrainingComprehensive Training
DMG Service Solutions
DMG in the aerospace industry:Your demands are our benchmark
MO
NTFO
RT
WERBUNG
FLY
.SD
3922
/080
6US
Tec
hnic
al u
pdat
e ri
ghts
res
erve
d. We automate your production
Workpiece handling with robot Flexible pallet systems
he 3 main groups in the
MG application spectrum:
| Structural components
| Engine components
| Landing gear com-
ponents
FLY_SD3922_Aerospace_us 23.08.2006 13:57 Uhr Seite 6
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